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Effects of Helical Tube Electrode Structure on Mixed Machining Product Transfer in Micro-Machining Channel during Tube Electrode High-Speed Electrochemical Discharge Machining

by Yan Zhang 1,*, Chen Wang 1, Yu Wang 2, Lei Ji 1, Jian Tang 1 and Qin Ni 1
1
School of Mechanical and Power Engineering, Nanjing Tech University, Nanjing 211800, China
2
AECC Sichuan Gas Turbine Research Establishment, Chengdu 610500, China
*
Author to whom correspondence should be addressed.
Micromachines 2019, 10(10), 634; https://doi.org/10.3390/mi10100634
Received: 12 August 2019 / Revised: 19 September 2019 / Accepted: 20 September 2019 / Published: 22 September 2019
(This article belongs to the Section D:Materials and Processing)
In tube electrode high-speed electrochemical discharge machining (TSECDM), mixed products are constantly produced in the narrow machining gap by simultaneous discharge erosion and electrochemical dissolution. For the high-efficiency removal of these products from the machining gap, a tool electrode with an optimized helical structure was utilized in TSECDM in this study. Firstly, the concentration distributions of the processed products in the machining gap using tube electrode tools with three typical helical structures were studied through the simulation of solid–liquid coupling; this showed that a trapezoidal helical structure benefited the reduced accumulation of products in grooves and the effective removal of products from the machining gap. Secondly, the main geometric parameters of the trapezoidal helical structure, including the helical groove depth, pitch, and tooth angle, were optimized by gap flow-field simulation to enhance the removal effect on processed products. Finally, it was verified that the trapezoidal helical electrode showed a definitive and significant advantage over the ordinary cylindrical electrode in effectively removing processed products from the machining gap by the comparison of flow-field simulations and actual machining experiments. View Full-Text
Keywords: electrical discharge machining; electrochemical machining; helical tube electrode; structural optimization; flow field simulation; machining by-products electrical discharge machining; electrochemical machining; helical tube electrode; structural optimization; flow field simulation; machining by-products
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Zhang, Y.; Wang, C.; Wang, Y.; Ji, L.; Tang, J.; Ni, Q. Effects of Helical Tube Electrode Structure on Mixed Machining Product Transfer in Micro-Machining Channel during Tube Electrode High-Speed Electrochemical Discharge Machining. Micromachines 2019, 10, 634.

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